IC C. UNITED STATES

{ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE 201 645

KL.] J REGION I

970 BROAD STREET

NEWARK. NEW JERSEY 07102

August 20, 1970

J. P. O'Reilly, Chief, Reactor Inspection and- /

Enforcement Branch, Division of Compliance, HQ

CONSOLIDATED EDISON COMPANY (INDIAN POINT 3) DOCKET NO. 50-286

The attached report of inspection of Consolidated Edison Company's Indian Point No. 3 construction site, conducted July 14 through 16, 1970, is forwarded for information.

Two items of nonconformance were found. Welding of carbon steel to stainless steel in the refueling canal liner was being performed without a qualified procedure (P-i to P-8), and the welding procedure (P-1 to P-l) for Class I carbon steel piping does not stipulate the flow rate of the gas for purging and shielding and specifies two pre-heat rates which vary by more than 100 F.

Repair of the containment liner deviation has been started. Procedures for correcting the deviations were reviewed and approved by UE&C, Westingho use and Consolidated Edison.

Z, .E.M. Howard Senior Reactor Inspector

cc: E. G. Case, DRS (3) P. A. Morris, DRL R. S. Boyd, DRL (2) R. C. DeYoung, DRL (2) D. J. Skovholt, DRI (3) P. W. Howe, DPL (2) L. Kornblith, Jr., CO Regional Directors, CO PEG Files

.02977

q l I oS I 0

RECEIVED

1970 AUG 24 A 1 9 (7

A .U.S ATO ifr E N,' CoM O lti,-, COM PLIANCE

U. S. ATOMIC-ENERGY COMMISSION REGION I

DIVISION OF COMPLIANCE

Report. .of Inspection

CO Report No. 286/70-4

CONSOLIDATED EDISON COMPANY

Indian Point No. 3 (IP-3)

"i6nt'iuction Permit No. CPPR-62

Category A

Dates of Inspection: July 14, 15 and 16, 1970

Dates of Previous Ins.ectiop: -2 larch 24 and 25, 1970

Inspected by: R. F. Heishman, Principal Reactor Inspector

R. L. Brown, Reactor Inspector (Construction)

D. E. Whitesell,.Reactor fnspector (Construction)

Reviewed by:M. Hwr Se ra to E. M. Howard, Senior',Reactor Inspector

Proprietary Information:

Date

Date

Date /

Date

None

Scope

A routine announced inspection of the 3023 MWT Pressurized Water reactor

(Indian Point No. 3) Construction site;at Buchanan, New York, was conducted

on July 14, 15 and 16, 1970. The--inspection was directed toward the require

ments of Attachment C, "Containment", Attachment E, "Other class I Structures,"

Attachment F, "Reactor Coolant-Pf ssure Boundary Piping" and Attachment G,

"Other class I Piping" of Provisional Instruction 3800/2 and other outstanding

inspection items.

Summary

Safety Items

None 02977

Licensee:

co

RECEIVED

1970 AUG 24 PAI 9 17

!US. ATOIrC EIERGY COMMj. SDl I \q j CF .COM1PLrANCE

I. ..' I

-2

Nonconformance Items

1. The PSAR in Supplement to Sunmary of Application dated February 20, 1969, Appendix D, Section III-B states in Part, "The UE&C Field Quality Control group shall-*.. 3. Assure that Vendor Materials documentation and construction conform to the requirements and intent of applicable specifications, drawings and procedures."

Contrary to the statement above, no approved welding procedure was available for welding carbon steel to stainless steel (P1 to P8). for the refueling canal liner required by Specification No. 9321-05-225-3 which specifies welding procedures will be qualified in accordance with Section IX ASME B&PV code.

2. The PSAR in Supplement to Summary of Application date February 20, 1969, Appendix D, Section VI, F. 2. states in part,"Welders and Welding procedures will be certified in accordance with ASME Code requirements."

ASME Code, Section IX, paragraph Q-II states: "The Welding procedures must be set up as a New Procedure Specification and must be completely requalified when any of the applicable changes listed below are made in the procedure.: ,. V-5 (a) A decrease of 100 F or more in the minimum specified preheating temperature.: . . . V-10 (b) An increase of 25 percent or more, or a decrease of 10 percent or more in the rate of flow of shielding gas or mixture.

Contrary to the statement above, Courter's Welding Procedures No. I & 20 for field welding carbon steel to carbon steel (PI to P1) does not stipulate the flow rate of the gas for purging and shielding. Two preheat temperatures are stipulated; one for 200°F if the carbon content is 0.15 percent - 0.20 percent; and 500OF if the carbon content is 0.20 percent - 0.35 percent.

unusual Occurrences

None

Status of Previously Reported Problems

1. Staggering of Horizontal Rebar Splices (CO Report No. 286169-5)

The previously reported problem of inproper horizontal separation of rebar splices in the containment wall has been resolved by engineering evaluation and replacement of cadwells where possible. An engineering evaluation by the designer (UE&C) was performed to

- 3 -

evaluate those areas where the splices could not praticably be replaced and was approved by Con Ed. Consolidated Edison indicated that the eva

luation was discussed with Dr.oGluckman and DRL, This iLei is consi-.

dered resolved.

2. Quality Control Assumption by WEDCO (CO Report No. 286/69!L

Wedco assumed first level Quality Control responsibility of Indian

Point No. 3 on April 20, 1970, replacing UE&C. The change was approved by Con Ed for IP2 and 3 and reported for IP2 only to

the AEC under Docket No. 50-247 (Indian Point No. 2);. however,

no documentation has been submitted regarding the assumption of Quality

Control responsibility by Wedco at Indian Point No. 3. This item

remains outstanding.

3. Containment Out-of-Round (CO Report No. 286/70-2)

CB&I has developed a plan for correction of containment liner devia

tions which is outlined in a letter from CB&I to Wedco dated February

24, 1970. This plan was reviewed and approved by the designer (UE&C) and by the Westinghouse, PWR Systems Division in a letter from Mr.

R. F. Devine, Manager, Architect Engineering, Westinghouse to Mr. J.

J. Grob, Jr., Con Ed dated May 13, 1970. Con Ed concurred with this

method of repair and the repair is in progress.

Repair consists of using jacking pipes, wedges and mechanical jacks

braced against timber softeners on the crane wall to return the shell

of the liner to tolerance. At areas of maximum variation, either

vertical wide flanges or horizontal angles were installed as

softeners for the jacking pipe. This was to be followed by thorough

examination of plates at jacking points for assurance that no local deformations resulted. Visual inspection of all plate-to-plate welds

and plate-to-channel welds at the jacking points and retest of weld

pressurization system was required. In addition the results of the

above will be documented and made a part of the QC records. CO:I

will review this documentation when completed. This item remains

outstanding.

4. WEDCO Procedure, (Calibration Frequency) (CO Report No. 286/70-2)

The Wedco procedure describing the frequency for calibrating the

equipment used for calibration and test was not completed at the time of the inspection. A completion date of September 15, 1970 was

given to the inspector by Wedco. This item remains outstanding.

-4

5. Concrete Repairs (CO Report No. 286/70-3)

a. Crack in Floor Slab of Primary Auxiliary Building (PAB)

Investigation of the small crack in the floor slab at elevation 34 feet of the PAB revealed the crack to be slight. The investigation consisted of probing and chipping to solid concrete ( 3-inches) after which repairs were completed by grouting. The inspector reviewed the documentation and found it to be adequate. This item is considered resolved.

b. Polar Crane Wall (Biological Shield) Honey Combing (CO Report

No. 286/70-2)

The 2-feet by 2-feet area in the polar crane wall reported as a possible area of honey combing was investigated by probing and chipping. The results indicated only surface voids which were repaired by hand placed mortar after removal of the defective

concrete. This item is considered resolved.

c. Containment Floor Slab Cracks (CO-Report No. 286/70-2)

The surface cracks in the containment floor slab (elevation 46

feet) have been investigated, by chipping, probing, and visual examinations and found to be surface conditions. The plan is to use EPOLITH patcher, which is an epoxy patching compound for

concrete, to repair the surface cracks. The manufacturer of the patching compound is currently writing a procedure for preparation

of the surface to be repaired which will be utilized in the repair of these cracks. This item remains outstanding pending the comple.ted repair and review of the documentation by CO:I.

6. Cadwell Difficulties (CO RI&E, Memo September 20, 1969)

The faulty cadwell powder discussed in memo, Reactor Inspection and

Enforcement Branch, CO:HQ, dated September 20, 1969 has been discussed with the licensee. Verification by the licensee, that the

powder used in cadwelding at IP-3 was not from the faulty lots, has been accomplished. This item is considered resolved.

7. Anchor Valves (CO. RI&E, Memo February 18, 1970)

The use of Anchor Valves was discussed with the licensee in accordance with and in the context described in Memo, Reactor Inspection and Enforcement Branch, CO:HQ, dated February 18, 1970. No valves

are being procured from Anchor according to the licensee. This item is considered resolved.

- 5 -

8. Concrete Pumped through Aluminum Pipe (CO RI&E Memo, April 22, 1970)

In accordance with memo, Reactor Inspection and Enforcement Branch,

CO:HQ, dated April 22, 1970, the use of aluminum pipe for pumping

concrete was reviewed. Con Ed stated that aluminum pipe for pumping

concrete had not and would not be used. Wedco (UE&C) concrete

specifications prohibit the use of aluminum pipe for pumping concrete.

This item is considered resolved.

9. ATAPCO piping (CO RI&E, Memo, December 8, 1969)

Discussions were held with Con Ed in accordance with memo, Reactor

Inspection and Enforcement Branch, CO:HQ, dated December 8, 1969

regarding ATAPCO piping. The licensee stated no piping was being

procured from ATAPCO. This item is considered resolved.

Other Significant Items

1. Branch Radiography Laboratory, Incorporated has been awarded a contract

by Wedco to provide nondestructive testing for Unit No. 3.

2. The Reactor Pressure Vessel is scheduled to be shipped to the site

for storage on or about July 25, 1970. No approved procedures for

handling and storage were available.

Containment (Attachment C,PI 3800/2)

The containment vessel is supplied complete by CB&I who is responsible for

supplying material, shop fabrication, site erection, welding, inspection and

testing.

The inspector was unable to determine if CB&I procedures and other documents

covering their activities do exist, because CB&I management personnel were not

on the construction site in sufficient time to arrange an audit during this

inspection.

The inspection reviewed the Con Ed, Wedco, and CB&I documents (specifications,

procedures, drawings, records, etc.) that were available. The following

procedural deficiencies were found:

1. Weld Material Control procedure not available (4805.04-g).

2. Detail drawings do not specify the applicable welding procedure for

a specific weld (5405.04-f4).

0

-5

8. Concrete Pumped through Aluminum Pipe (CO RI&tE/emo, April 22, 1970)

In accordance with memo, Reactor Inspection nd Enforctment Branch,

CO:HQ, dated April 22, 1970, the use of al inum pipe for pumping

concrete was reviewed. Con Ed stated that/aluminum pipe for pumping

concrete had not and would not be used. Wedco (UE&C) concrete

specifications prohibit the use of aluminum pipe for pumping concrete.

This item is considered resolved/

9. ATAPCO piping (CO\RI&E, Memo, December/8, 1969) \ / Discussions were eld with Con Ed in accordance with memo, Reactor

Inspection and Enf rcement Branch, C P:HQ, dated December 8, 1969

regarding ATAPCO p ping. The licen ee stated no piping was being

procured from ATAP . This item i considered resolved.

Other Significant Items

1. Branch Radiography Laoratory, I corporated has been awarded a contract

by Wedco to provide n ndestruct~ve testing for Unit No. 3.

2. The Reactor Pressure V sel is scheduled to be shipped to the site

for storage on or aboutJuly 5, 1970. No approved procedures for

handling and storage wee av il.

Containment (Attachment C,P 3800 )

The containment vessel is supplie complete by CB&I who is responsible for

supplying material, shop fabricat n, site erection, welding, inspection and

testing.

The inspector was unable to dete in if CB&I procedures and other documents

covering their activities do ex'st, ecause CB&I management personnel were not

on the construction site in suf icient time to arrange an audit during this

inspection.

The inspection reviewed the Co Ed, Wed o, and CB&I documents (specifications,

procedures, drawings, records etc.) th t were available. The following

procedural deficiencies were ound:

1. Weld Material Contro procedure n t available (4805.04-g).

2. Detail drawings do ot specify the applicable welding procedure for

a specific weld (54 5.04-f4).

-5- /

8. Concrete Pumped through Aluminum Pipe O RI&E Memo, April2, 1970)

In accordance with memo, Reactor Insp Ction and Enforcement Branch,

CO:HQ, dated A r 22, 1970, the use Of aluminum pipe for pumping

concrete was revipwed. Th Con Ed s ated thht aluminum pipe for pumping

concrete had not nd would not be usled. Wedco (UE&C) concrete

specifications ,'pro ibit the use of aluminum pipe for pumping concrete.

9. ATAPCO i ~in& (CO R &E, Memo, Decmber 8, 1969)

Discussions were hel with Con E. in accordance with memo, Reactor

Inspection and Enforc ment Bran , CO:HQ, dated December 8, 1969

regarding ATAPCO pipi .The 1 censee stated no piping was being

procured from ATAPCO. This it m is considered resolved.

Other Significant Items

1. Branch Radiography Labor tor,, Incorporated has been awarded a contract

by Wedco to provide nonde tluctive testing for Unit No. 3.

2. The Reactor Pressure Vesse is scheduled.to be shipped to the site

for storage on or about J 25, 1970. No approved procedures for

handling and storage were a ailableo

Containment (Attachment C,PI 380 /2

The containment vessel is supp ied c mplete by CB&I who is responsible for

supplying material, shop fabric tion, site erection, welding, inspection and

testing.

The inspector was unable to d termine i CB&I procedures and other documents

covering their activities do xist, beca se CB&I management personnel were not

on the construction site in s fficient t e to arrange an audit during this

inspection.

The inspection reviewed the on Ed, Wedco, and CB&I documents (specifications,

procedures, drawings, recor , etc.) that re available. The following

procedural deficiencies wer found:

1. Weld Material Cont 1 procedure not a ailable (4805.04-g).

2. Detail drawings do not specify the app icable welding procedure for

a specific weld ( 05.04-f4).

- 6-

Other Class I Structures (Refueling Canal) (Attachment E, PI 3800/2)

The refueling canal was selected for inspection under A .tachement E, PI 3800/2. The following significant items were found:

1. No approved welding procedure for welding P1 to P8 material was available for inspection.

2. No weld material control procedures were available for inspection

3. Inconsistencies exist between the specification, welding procedure and actual practice for electrode to be used when welding P8 to P8 material.

4. No NDT procedures were available for inspection.

Piping (Attachments F and G, PI 3800/2)

Reactor Coolant Piping and Main Steam Piping were inspected using applicable portions of Attachments F and G, PI 3800/2. The following significant items were found:

I. Grade 308 filler metal is used in joining grade 316 base metals, (Attachment F, 4805.04-a.li) /

2. Weld procedure qualification certifications do not meet Section IX of the ASME Boiler and Pressure Vessel Code. (Attachment F and-G 4805.04-a.1.2)

3. NDT techniques are not required to be qualified. (Attachment F, 4805.04 a.3)

4. Acceptance standards have been omitted from Branch's NDT techniques for dye check and magnetic particle.

5. Branch's dye penetrant technique permits the use of trichloroethylene and perchlorethylene for cleaning stainless steel. (Attachment F,! 4805.04 e.4)

6. Wedco does not have written procedures for issue control of weldin consumables in order to maintain the identity and traceability of such consumables in the work. (Attachment F, 4805.04 g.3)

7. There is no procedure or instructions relative to the disposal of unused materials. (Attachment F 4805.04 g.5)

- 7 -

8. No provisions were found relative to the removal and repair of arc

strikes. (Misc.)

Management Interview

An exit management interview was held on July 16, 1970. The following

personnel were in attendance:

Consolidated Edison Company

Mr. J. A. Corcoran, Site Superintendent

Mr. E. J. Dadson, QA Engineer

Mr. F. M. Matra, IP3 project Superintendent

WEDCO Corporation

Mr. E. J. Staffel, Technical Assistant to Executive Vice President

Mr. M. L. Snow, Manager, PA and Reliability

Mr. J. P. Knight, Manager, Quality Planning

Mr. T. A. Lawson, Manager, Quality Control

The following significant items were discussed:

1. Containment (Attachment C, PI 3800/2)

The inspector stated no procedures for welding material control for

the containment subcontractor (Chicago Bridge and Iron) was found.

Mr. Dadson stated that because CB&I was not on site at the time of

the inspection, the findings should be deferred until review of CB&I

methods and procedures could be determined. The inspector stated

these items would be reinspected when CB&I was available on site.

2. Refueling Canal (Attachment E, PI 3800/2)

The inspector stated the specifications for the refueling canal

specified welding P8 to P8 material would be with 308SS or 310 SS

filler metal. The welding procedure specified using 308SS filler

metal and actual welding observed by the inspector was being done

with 309SS filler metal. In addition the welders qualification

records indicated use of 309SS electrode. Mr. Dadson stated

corrective action would be taken, The inspector further stated

mill certs for filler metal showed SS310 for shipments 1 through 5

and SS309 for shipment 6 with no change in the specification. Mr.

Snow stated a complete audit of records would be performed and

corrective action taken as required. The inspector stated the

records system appeared marginal as evidenced by the lack of

documents in the files labeled "Refueling Canal Specification 9321 05-225-3, mill certs. and other QC documentation°" Numerous documents were asked for by the inspector which were later found in other parts of the files. Mr. Snow asknowledged the inspectors' comments and stated manpower problems and other extenuating circumstances had caused the temporary problem. Mr. Corcoran stated there was no excuse for the situation and prompt corrective action would be taken. On July 24, .19.70, Mr. Dadson, Con Ed, called Mr. Heishman CO:I and stated the responsibility for maintenance of site QC records was being transferred from the Wedco QC Manager to the Wedco Quality Planning Manager effective August 17, 1970 and an audit of IP3 QC records was in progress.

3. Piping (Attachment F and G, PI 3800/2)

The inspector stated no evidence of engineering analysis was found to support the changing from grade 316 filler metal to grade 308 filler metal in welding grade 316 base metals. Mr. Dadson stated Westinghouse had made the analysis and copies of the reports would be available during the next inspection. The inspector stated inconsistencies existed between the welding contractor's procedures and certain code requirements. These include omission of gas flow rates for purge shielding and post weld heat treat range, stipulated as 1,0000F - 1,200°F in the procedure while the code requires a range of l,100°F - 1,2000 F.

Mr. Snow stated these inconsistencies would be included in the complete audit-and modification of the procedures for welding on IP3. The inspector stated the inconsistencies between procedures and code requirements indicated the subcontractor documents were not being reviewed as thoroughly as the Wedco QA plan indicated.

The NDT subcontractor's (Branch Laboratories) procedures for LP and MP techniques did not specify the acceptance standards and qualification certificates were lacking. Mr. Snow stated this item would be corrected.

Persons Contacted

Consolidated Edison Company

Mr. J. A. Corcoran, Site Superintendent

* 0

9

Mr. E. J. Dadson, QA Engineer Mr. F. M. Matra, IP3 Project Superintendent Mr. C. H. McDonnell, US Testing Company

WEDCO Corporation

Mr. M. Snow, Manager, QA and Reliability Mr. T. Lawson, Manager, Site Quality Control Mr. J. Knight, Quality Planning Mr. S. Roberts, Reliability Engineer Mr. J. J. Ford, Structural Engineer Mr. J. Jaillet, QC-NDT Field Supervisor Mr. R. Viola, QC-NDT Supervisor Mr. J. Schmidt, QC Records Mr. H. Werle, Chief Mechanic Mr. R. Gerdoney, Welding Foreman, McCormack - Champion Company Mr. S. Farrell, General Foreman, Boilermakers, McCormack - Champion Co.

Status of Construction

Mr. Matra informed the inspector that the status of construction on July 1, .1970 was 36 percent complete.

* NDT Subcontract

Branch Radiography Laboratory, (Branch) Incorporated has been awarded a contract by Wedco for nondestructive testing as directed by the Wedco QC Manager for Indian Point No. 3. This contract commits Branch to the Wedco Specification RT70, Radiographic Testing Procedure and Wedco has approved the Branch Procedures for UT, MP and LP. This contract excludes the containment liner NDT and other subcontracts which have a requirement to provide NDT.